Fluid pump

ABSTRACT

The present invention relates to a fluid pump having an improved performance. The pump comprises an impeller, volute housing, inner housing geometry, and an adapter. The impeller is configured to generate fluid flow velocity. The volute housing is configured to improve fluid pump performance while reducing power consumption, the volute housing comprises the inner housing geometry. The inner housing geometry is configured to convert the fluid flow velocity that has been generated into pressure. The adapter is designed to protect the unconnected end of the drive shaft and reduce the negative effects of shaft deflection. The adapter also has a structural rib geometry which is configured to provide superior structural integrity at a minimal mass.

BACKGROUND OF THE INVENTION

The present invention relates to centrifugal pumps used in industrial applications to process fluids and slurries, and specifically relates to improvements to centrifugal pumps having an optimized volute housing, impeller, and adaptor each configured to more efficiently process fluids and/or slurries.

Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically comes from an engine or electric motor. The fluid enters the pump impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially outward into a diffuser and collection zone, from where it exits. Common uses of these pumps include water, sewage, petroleum and petrochemical pumping. These pumps can be installed in systems applied to a variety of different industries including (but not limited to) agriculture, industrial, marine, and OEM. The present invention optimizes these pumps by substantially improving performance while reducing shaft power all of which is accomplished through improvements to various pump components, discussed herein.

SUMMARY OF THE INVENTION

The present invention relates to a fluid pump having an improved performance. The pump comprises an impeller, volute housing, inner housing geometry, and an adapter. The impeller is configured to generate fluid flow velocity. The volute housing is configured to improve fluid pump performance while reducing the pump's overall power consumption, the volute housing has a fluid intake, fluid discharge, and inner housing geometry. The inner housing geometry is configured to convert the fluid flow velocity that has been generated into pressure. The adapter is designed to protect the unconnected end of the drive shaft and reduce the negative effects of shaft deflection. The adapter also has a structural rib geometry which is configured to provide superior structural integrity at a minimal mass.

The impeller comprises a hub profile, outer diameter, impeller eye, and plurality of impeller blades. The impeller eye is centrally located on the body of the impeller and is configured to connect to one end of a drive shaft. Each of the plurality of impeller blades is connected to the hub profile and forms a plurality of flow channel areas that are interposed between two of the impeller blades. Each flow channel area also gradually diverges from the impeller eye to the outer diameter.

The inner housing geometry comprises a volute area, secondary passage, and diffuser. The volute area has a secondary passage and circulation zone. The secondary passage is interposed between the volute area and a collection zone. The secondary passage is configured to allow fluid reentry into the volute area during priming and non-reentry after full prime has been established. The diffuser is located at the periphery of the volute area and is configured to alleviate wasted energy conversion, the diffuser also has a discharge point within the volute area. This discharge point is configured to suppress vortex fluid separation as fluid flow passes through it. The fluid flow also passes the discharge point at an optimum fluid flow velocity for both pressure conversion and reduction of fluid separation. The collection zone is positioned to receive fluid flow that has passed beyond the diffuser and it is positioned to maintain pressure conversion. The secondary passage and diffuser operate in conjunction during priming to effectively separate gases from the fluid.

In certain embodiments, the fluid pump comprises a plurality of flanges attached to the fluid intake and the fluid discharge. These flanges enable the fluid pump to connect with external fluid conduits. In other embodiments, the fluid pump further comprises a wear plate joined to the impeller. Each flow channel area is interposed between the wear plate and hub profile.

In any embodiment of the pump, the flow channel areas may be shaped to generate a gentle fluid flow velocity. The adapter may also comprise an ergonomic handle. Moreover, this ergonomic handle may be constructed from sheet metal and connected to a molded pocket within the adapter. The volute housing may also comprise an indentation that corresponds to the secondary passage. This indentation is to facilitate volute area fluid reentry into the volute area during priming and non-reentry after full prime is established. The structural rib geometry of the adapter may also further comprise a plurality of horizontal ribs connected to a vertical rib.

The diffuser may also be sized and located in a precisely calculated way that maintains pressure after the fluid flow has escaped the volute area. Each impeller blade may also have a blade angle that facilitates performance of the fluid flow velocity that is generated. Each impeller blade may also further have a blade thickness that is designed to facilitate this generated fluid flow velocity. The hub profile of the impeller may also have a tapered shape that is designed to also facilitate this generated fluid flow velocity. The volute housing may also be made from a non-corrosive metal. The impeller may also be made from a non-corrosive metal. The volute area may comprise a third passage which is configured to allow for the escape of gasses during priming.

Numerous applications, some of which are exemplarily described below, may be implemented using the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an embodiment of the fluid pump;

FIG. 2 is a perspective side view of the fluid pump of FIG. 1;

FIG. 3 is an exploded view of the fluid pump of FIG. 1;

FIG. 4 is a cutaway front view of the volute housing of the fluid pump of FIG. 1;

FIG. 5 is a cutaway side view of the volute housing of the fluid pump of FIG. 1;

FIG. 6 is top view of the impeller of the fluid pump of FIG. 1;

FIG. 7 is a cutaway side view of the impeller of the fluid pump of FIG. 1;

FIG. 8 is side view of the impeller of the fluid pump of FIG. 1;

FIG. 9 is a perspective view of the adapter of the fluid pump of FIG. 1;

FIG. 10 is a side view of the adapter of the fluid pump of FIG. 1; and

FIG. 11 is a chart exemplifying the efficiency of the fluid pump of FIG. 1.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate currently preferred embodiments of the present invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to the drawings in detail, and specifically to FIGS. 1-3, reference numeral 10 generally designates an exemplary fluid pump (“pump”) having an improved performance in accordance with an embodiment of the present invention. The pump 10 may be able to discharge fluid flows of up to 180 GPM and 97 TDH. The pump 10 generally includes a volute housing 12 having a closed, semi-axial construction and, being made from non-corrosive metal, the volute housing is designed to improve pump 10 performance while reducing the overall power consumption for the pump 10. To effectively accomplish this, the volute housing 12 has an inner housing geometry therein which may be of a volute configuration, via a volute area, with an impeller 14 mounted for rotation within the volute area and generation of fluid velocity within the pump 10. A drive shaft 16 is operatively connected to the pump impeller 14 for causing rotation thereof, and enters the pump housing from the back side. The unconnected end of the drive shaft 16 is protected by an adapter 18, which also reduces shaft deflection. The pump may further include a fluid discharge 20, typically at the top of the pump 10 with respect to the drive shaft 16 and a fluid intake 22 located at the opposite side of the volute housing 12 from the drive shaft 16.

A discharge flange 24 is joined to the fluid discharge 20 via joining mechanisms 26 such as screws. An intake flange 28 is joined to the fluid intake 22 also via joining mechanisms 26. These flanges 24, 28 enable the pump 10 to connect with external fluid conduits (not shown) and are typically either embodied as a 1.5″ NPT port flange or a 2″ NPT port flange but may be embodied in some other form.

Referring now to FIGS. 4 and 5, the inner housing geometry 30 is configured to convert the fluid velocity generated by the impeller into pressure. The inner housing geometry 30 includes the volute area 32 immediately connected to the fluid intake 22, by way of an inlet passage 71, and incorporates a secondary passage 34, a third passage 80, and a circulation zone 36. The inlet passage 71 allows fluid to remain in the pump 10 while the impeller 14 both generates fluid velocity and does not generate fluid velocity. Allowing fluid to remain in the pump, during these two stages (the rotary on-off stages), assists with priming the pump.

The configuration of the geometry of the volute area 32 gradually and continuously changes as it extends about the circumference of the volute housing 12, optimizing the hydraulic interaction between the impeller and fluid flow, to provide stable fluid flow performance and pressure throughout. The secondary passage 34 and third passage 80 are interposed between the wall 40 of the volute area 32 and a collection zone 38 (otherwise known as a collection chamber). Across the secondary passage 34 from the tip of the wall 40 is a diffuser 42, which is at the periphery and partially flanks the volute area 32. The length of the diffuser 42 and its location with respect to the inner housing geometry 30 are calculated precisely to maintain pressure within the volute housing 12 during pump 10 operation. The collection zone 38 is directly connected to the fluid discharge 20. A collection wall 44 physically separates the collection zone 38 from fluids entering the pump 10 through the fluid intake 22 via inlet passage 71. It should be understood that many sealing materials and joining mechanisms are excluded from the discussion herein, but may still be incorporated into the invention.

The surfaces of the inner housing geometry 30 may be readily finished with a high degree of precision so as to reduce fluid flow drag resistance. The same holds true for the external surfaces on the volute housing 12. In certain instances, these surfaces will be treated by grinding or by an analogous material removal technique.

While priming the pump, as fluid is being introduced into the volute housing 12, it can easily flow pervasively throughout. Fluid is able to escape and reenter the volute area 32 and collection zone 38 via the secondary passage 34 and third passage 80. The volute housing 12 has an indentation 41 in it that creates a bulge in the inner housing geometry 30, corresponding to the secondary passage 34, so as to help form the functional shape of the secondary passage 34. During priming, the indentation 41 facilitates the fluid to escape and reenter the volute area 32 and collection zone 38. Moreover, fluid is also able to flow directly around the diffuser 42 while escaping and reentering the volute area 32 and collection zone 38. This freedom of fluid flow ensures that trapped gases are sufficiently expelled from the fluids prior to the beginning of pump operation. The third passage 80 also facilitates the escape of any trapped gasses into collection zone 38, during the priming of the pump 10.

After pump operations have begun, suction force, generated by the rotation of the impeller, creates a fluid flow that enters the pump 10 through the fluid intake 22. The pervasive fluid flow then travels to the center of the volute area 32 where it will interact with the impeller and be projected axially with a certain velocity, discussed below, before being discharged from this area via a discharge point 46 at the end of the diffuser 42 that flanks the volute area 32. The discharge point 46 is configured to suppress vortex created separations of fluids as they flow past the discharge point 46 which, in turn, alleviates wasted energy conversion of the fluids within the volute housing 12. During typical operations of the pump 10, the fluid flow passes through the discharge point at an optimum velocity for both pressure conversion and the reduction of fluid separation. The pressure is maintained as the fluid flow passes through the diffuser 42 and keeps any fluid flow from being able to back wash back into the volute area 32. Fluid flow not immediately discharged via the diffuser 42 is axially projected into the circulation zone 36, where it will circulate around the outer perimeter of the impeller until escaping the volute area via the discharge point 46. This circulation also reduces fluid separation in the pump 10.

After being expelled beyond the diffuser 42, the collection zone 38 receives the fluid flow. The tapered shape of the collection zone 38 maintains the pressure conversion within the volute housing 12 and stabilizes the fluid flow. The formed shape of the secondary passage 34 blocks the fluid flow during full pump operation such that the flow will remain in the collection zone 38 and is not able to reenter the volute area 32.

In many instances, prior art pumps have diffusers that comprise angled spoilers at their discharge point. It has been found that such spoilers substantially hinder the performance of the fluid flow while escaping the respective volute area. These spoilers create a vortexing fluid separation as the fluid flow passes the discharge point, which effectively wastes energy within the volute housing. Prior art pumps also typically comprised diffusers that are sized and positioned in such a way that they reduce the pressure of the fluid flow after it escapes the volute area. These diffusers are often too large to maintain pressure. These prior art diffusers can also create an escaping fluid flow velocity that in effect is so fast it causes fluid separation.

Referring now to FIGS. 6-8, the impeller 14 is made from non-corrosive metal and comprises a hub profile 48, an outer diameter 50, and an impeller eye 52. The impeller eye 52 is centrally located on the impeller 14 and is shaped to connect and interlock with the drive shaft, when the pump is constructed for operation. Connected to one side of the hub profile 48 is a plurality of evenly spaced impeller blades 54, in which there are three in this embodiment of the impeller 14. These impeller blades 54 are of a generally constant height along their length. The leading edge of the impeller blade 54 abuts the impeller eye 52 while the outer tailing edge is at the outer diameter 50 of the impeller 14. It should be understood that the impeller blades 54 may be referred to as backward-curving when viewed with the direction of rotation. A wear plate 60 (FIG. 3) may also be joined to the impeller 14 such that it encloses the impeller blades 54.

Flow channel areas 56 are formed by the horizontal space interposed between each set of impeller blades 54. As such, when there are three impeller blades 54, there will correspondingly be three flow channel areas 56. In the instances a wear plate 60 is incorporated, the flow channels are interposed vertically between the wear plate 60 and hub profile 48. The flow channel areas 56 each have an inlet region that is near the impeller eye 52 and a discharge region located at the impeller's 14 outer diameter 50. The impeller blades are angled 58 in such a way that each flow channel area 56 diverges in a gradual manner from formation at the impeller eye 52 until ending at the outer diameter 50. As such, the discharge region is substantially wider than the inlet region so that the flow channel area is generally V-shaped. Each impeller blade 54 may also have a designed thickness that facilitates the generated fluid flow velocity. Other embodiments of the impeller blades 54 may be longer or shorter than is shown in the figures.

As the impeller 14 rotates, fluids reaching the impeller 14 at the impeller eye 52 are centripetally forced in an axial direction towards the outer diameter 50, through each of the flow channel areas 56. The diverging V-shape of the flow channel areas 56 causes the generated fluid flow at a gentle velocity throughout the flow channel areas, which helps reduce any fluid separation. The radially tapered shape of the hub profile 48 also facilitates this gently generated fluid flow velocity. The impeller 14 is adapted to rotate at different speeds to generate various required pressures within the volute housing 12.

Referring now to FIGS. 9 and 10, the adapter 18 is made from non-corrosive metal and has a structural rib geometry that provides superior structural integrity at the least amount of mass possible. The rib geometry incorporates two corresponding horizontal ribs 62 with vertical rib 64, creating structural design similar to an I-beam. The vertical rib 64 incorporates a centrally located orifice 66 that allows the drive shaft to extend outwardly. It has been estimated that, over prior art adapters, the mass of adapter 18 is decreased by approximately % 15 while its strength is increased by approximately 60%. The adapter 18 may include an ergonomic handle 68 (FIG. 3), constructed from non-corrosive sheet metal, connectedly locked to a molded pocket 70 on the body of the adapter 18 via a joining mechanism such as a cap screw. A second cap screw is located at the top of the sheet metal and forms the handle grip.

The optimized efficiency and performance characteristics of the pump 10 (FIG. 1) will now be shown and discussed with respect to the graph of FIG. 11. As shown, the data points for the pump are linearized and shown as solid lines. Other variables have been held constant. The curve 72 represents the pressure generated by the pump plotted against its flow rate. The curve 74 represents the pressure generated by prior art pumps plotted against that pump's flow rate. Depending on the specific point of flow rate, these curves show the pump having a 5 to 22 foot head increase over prior art pumps. The curve 76 represents the horse power generated by the pump plotted against its flow rate. The curve 78 represents the horse power generated by a prior art pump plotted against that pump's flow rate. Depending on the specific point of flow rate, these curves show the pump having a 0.1 horse power to an approximately 0.4 horse power reduction in shaft power from prior art pumps. As such, this graph shows marked improvement over the prior art pump.

It is also understood that when an element is referred to as being “on”, “connected to/with”, or “coupled to/with” another element, the element can be directly on, connected to/with or coupled to/with the other element or intervening elements may also be present. Furthermore, although the invention has been described with reference to preferred embodiments thereof, it is understood that various modifications may be made thereto without departing from the full spirit and scope of the invention as defined by the claims which follow. 

What is claimed is:
 1. A fluid pump having an improved performance, said pump comprising: a. an impeller configured to generate fluid flow velocity, said impeller comprising: i. a hub profile; ii. an outer diameter; iii. an impeller eye centrally located on said impeller and configured to connect to one end of a drive shaft; iv. a plurality of impeller blades connected to said hub profile and forming a plurality of flow channel areas interposed between two said impeller blades of said plurality of impeller blades; and v. wherein each said flow channel area of said plurality of flow channel areas gradually diverges from said impeller eye to said outer diameter; b. a volute housing configured to improve fluid pump performance while reducing power consumption, said volute housing having a fluid intake, a fluid discharge, and an inner housing geometry; c. said inner housing geometry configured to convert the generated fluid flow velocity into pressure, said inner housing geometry comprising: i. a volute area having a secondary passage and circulation zone; ii. said secondary passage interposed between said volute area and a collection zone, said secondary passage configured to allow volute area fluid reentry during priming and non-reentry after full prime is established; iii. a diffuser located at the periphery of said volute area and configured to alleviate wasted energy conversion, said diffuser having a discharge point within said volute area; iv. said discharge point configured to suppress vortex fluid separation as fluid flow passes through said discharge point; v. wherein fluid flow passes said discharge point at an optimum fluid flow velocity for both pressure conversion and reduction of fluid separation; vi. said collection zone positioned to receive fluid flow passed beyond said diffuser and to maintain pressure conversion; and vii. wherein said secondary passage and said diffuser operate in conjunction during priming to effectively separate gases from the fluid; and d. an adapter to protect the unconnected end of the drive shaft and reduce shaft deflection, said adapter having a structural rib geometry configured to provide superior structural integrity at a minimal mass.
 2. The fluid pump of claim 1 further comprising a plurality of flanges attached to said fluid intake and said fluid discharge, each said flange enables said fluid pump to connect with external fluid conduits.
 3. The fluid pump of claim 1 further comprising a wear plate joined to said impeller, said plurality of flow channel areas interposed between said wear plate and said hub profile.
 4. The fluid pump of claim 1 wherein said plurality of flow channel areas being shaped to gently generate fluid flow velocity.
 5. The fluid pump of claim 1 wherein said adapter comprises an ergonomic handle.
 6. The fluid pump of claim 5 wherein said ergonomic handle is constructed from sheet metal and connects to a molded pocket within said adapter.
 7. The fluid pump of claim 1 wherein said volute housing comprises an indentation corresponding to said secondary passage, said indentation facilitates volute area fluid reentry during priming and non-reentry when full prime is established.
 8. The fluid pump of claim 1 wherein said structural rib geometry comprises a plurality of horizontal ribs connected to a vertical rib.
 9. The fluid pump of claim 1 wherein said diffuser size and location is calculated precisely to maintain pressure after the fluid flow escapes the volute area.
 10. The fluid pump of claim 1 wherein each said impeller blade has a blade angle that facilitates performance of the generated fluid flow velocity.
 11. The fluid pump of claim 1 wherein each said impeller blade has a blade thickness designed to facilitate the generated fluid flow velocity.
 12. The fluid pump of claim 1 wherein said hub profile comprises a tapered shape to facilitate the generated fluid flow velocity.
 13. The fluid pump of claim 1 wherein said volute housing is made from a non-corrosive metal.
 14. The fluid pump of claim 1 wherein said impeller is made from a non-corrosive metal.
 15. The fluid pump of claim 1 wherein said volute area further comprises a third passage configured to allow the escape of gasses during priming. 